Second improved ball valve assembly

ABSTRACT

Described herein is an improved ball valve assembly for use in a tank or a tank-like container. This improved ball valve assembly prevents leakage of a liquid with corrosive and abrasive contaminants within the tank or a tank like container. This improved ball valve assembly is especially useful in a railroad tank car that contains a liquid commodity in whenever a tank is mobile and subjected to wide temperature variations. The improved ball valve assembly contains a ball component made of a ceramic material. A ceramic wiper (i) mechanically seals against the ball component and (ii) prevents contaminants from embedding within, or otherwise abrading, top and bottom seats within the ball valve assembly. Also contained in the preferred embodiment of this invention is an improved drive coupling that (i) eliminates the previously existing need for custom square drive tool (ii) pre-attached to the ball valve assembly. The current invention also includes an improved stem packing assembly that reduces the number of annular components along the stem of the ball valve assembly.

This application is a continuation in part of U.S. utility patentapplication Ser. No. 13/986,765 filed Jun. 3, 2013.

BACKGROUND OF THE INVENTION

The current invention is directed to ball valve assemblies that areconfigured to prevent leakage of liquids from within mobile tanks orother large tank-like containers. More particularly, but notexclusively, the current invention is directed to a ball valve assemblyconfigured to prevent leakage of liquid commodities from railroad tankcars. Railroad tank cars that ship liquid commodities are generallydivided into two categories: low pressure (general purpose) and (ii)high pressure tank cars. The present invention addresses general purposetanks as (i) railroad cars that transfer these commodities from the tankcars (ii) through a valve located at the bottom center position of thetank [′bottom outlet valve′]. These prior existing valves contain avariety of structures such as, but not exclusively, plug, butterfly orball valves. The most common prototype is the ball valve, and mostparticularly this invention pertains to the ball valve variety.

Current ball valve design does not solve the problem of contamination ofthe commodity liquid. Contaminants such as, but not exclusively, tankscale, dirt and debris at the bottom of a typical commodity tank, abradethe valve ball component and thereby result in leakage. These currentball valves also do not solve the problem of corrosion of ball valveassembly components. Abrasive materials embed in (i) the valve seat and(ii) score valve ball components generally made of stainless steel. Forexample, scratching as well as other abrasive or corrosion damage to aconventional metal ball component creates small channels that inevitablycause leakage of the liquid commodity even when the ball valve assemblyis ostensibly closed. To solve this problem, the current inventionimplements valve seats and valve balls generally made of a ceramicmaterial, and more particularly a specific ceramic material. Ceramicsare much harder materials than steel and not easily abraded bycontaminants. They are also very resistant to corrosion by chemicalliquid commodities carried in the tanks.

Midland currently produces bottom outlet ball valve Model No. 522 forrailroad tank cars. Midland's valve contains (i) seats made ofTeflon®/flouropolymer [TFE] or thermoplastic materials. Jamesburyproduces a bottom outlet ball valve with a polytetrafluorocarbon[hereinafter ‘PTFE’] valve seat for an effective seal between the ballcomponent and the seat. Ball components are generally comprised ofmetal, particularly stainless steel, in the ball valve assemblyindustry. Unfortunately, TFE and PTFE seats are particularly susceptibleto contaminants that embed in the seats and score the steel ballcomponents.

To solve this problem the current invention implements a componentdesignated as a ceramic wiper, and this ceramic wiper forms a rigidannular ring. When this ceramic wiper is combined with a ball componentmade of a ceramic material this wiper (i) substantially reduces scoringand corrosion of the ball component and (ii) prevents contaminants fromaccessing and embedding in the seats. The ceramic wiper is combined witha ceramic ball component to reduce abrasion of both these components. Insum, the current invention solves the industry leakage and corrosionproblems with (i) the sealing capability of a soft valve seat and (ii)the durability of ceramic components.

In previously existing devices of this particular industry, TFE and PTFEare the most widely used material for ball assembly valve seats becauseof their cost efficiency. Polyether ether ketone [hereinafter PEEK] hasexcellent mechanical and chemical resistance at higher temperatures thanPTFE. PEEK costs at least twice as much as PTFE, while the ceramicmaterial in the current invention is more costly than PTFE but not costprohibitive. The most preferred ceramic material for the currentinvention is zirconium oxide with preferably (i) tensile strength of70-85 kpsi and (ii) thermal expansion coefficient of 5.9e-06 per degreeCelsius. However, materials such as aluminum oxide compounds or siliconnitride are also satisfactory.

The current invention also solves the problem of handles which (i)pre-attach to a ball valve assembly and (ii) thereafter inadvertentlyswing open during transport of a liquid commodity. In the current art,whenever a tank car derails often the pre-attached valve assembly handledoes not predictably shear and fall from the ball valve assembly;instead the protruding handle remains intact and attached to the bottomoutlive valve at the railroad tank car bottommost surface. When theintact handle inadvertently swings opens during derailment, (i) thevalve assembly automatically opens and (ii) the liquid commodity poursfrom the tank car with financial, business, and environmentalconsequences.

For example, Midland's bottom outlet ball valve comprises a large longhandle that significantly protrudes from the valve assembly.www.midlandmfg.com/products/general-purpose-car/ball-valves on Apr. 8,2013. In a similar manner Jamesbury, Inc. discloses a ball valve with astandard attached handle. Seehttp://www.valvesandinstruments.com/jamesbury-ball-valves. Both Midlandand Jamesbury valve assemblies contains stems with male ends that solelyand exclusively accommodate proprietary handles. Consequently ball valveassembly handles are not interchangeable with each other or othercommercially available rotating operating devices. To solve this problemthe design of the current invention contains a drive coupling to whichconventional square drive tools can each operatively attach to the ballvalve assembly.

In sum, the current invention solves the handle problem by insertion ofthe new drive coupling so loading personnel may implement a ubiquitoussquare drive tool to operate the ball valve assembly. In addition tothis safety improvement, there is no additional sunk cost to implementand retrofit this drive coupling, because square drive tools areavailable at on loading and offloading railroad facilities. Furthermore,pending United States Department of Transportation regulations willrequire that all permanently affixed tools/handles be removed frombottom outlet valves. Consequently, the drive coupling of the currentinvention adaptor will solve the urgent need for compliance with thesepending regulations.

A third advantage of the current invention is the stem packing assembly.The stem packing assembly provides a seal between (i) a rotating stemand (ii) the stationary valve assembly body. Currently available stempacking assemblies comprise many forms such as woven graphite material,woven TFE rope and numerous TFE chevron rings. These components insertinto a stem longitudinal stem cavity between the rotating stem and valveassembly body. As the stem packing is increasingly compressed, thechevron rings (i) flare outward and (ii) thereby initially seal andcontact the cylindrical wall of the longitudinal stem cavity and stemexterior wall surface.

In these prior existing stem packing assemblies, the stem packing ismechanically compressed when the ball valve assembly is initiallyassembled. This initial compression deflects the conventionally placedBellville washers or wave washers whenever the ball valve assembly isinitially installed within a tank car. However, there is a long-feltneed to prolong the effective working life of the stem packing assembly:With long-term operation thereafter, this same stem packing with thecurrently available stem packing and spacers wears and inevitably creeps(by cold flow) away from the stem exterior surface. This processeventually reduces the effectiveness of the stem packing to seal betweenthe stem and the valve body inner surface. Consequently, because of therotating stem, wear of the stem packing requires progressive compressionagainst the stem longitudinal cavity as time progresses.

The current solution to this problem is not sufficient to preventleakage from the stem longitudinal cavity over time and rail carmovement. For example, many manufacturers currently include chevron PTFErings as (i) part of the ball valve assembly (ii) that is currentlycompressed by two spring loaded nuts with numerous supplementarycomponents. For example a Jamesbury valve comprises an indicator stop,reinforcing ring, compression ring, compression plate, disc spring andflat washer in addition to several chevron rings. In this previouslyexisting device, an applied force collectively compresses thecompression plate and these numerous rings against the stem packing. Incontrast, in the current invention, a single stem lock nut and anappropriate wave spring is threaded upon the stem. Single stem lock nutthereby forces a wave spring, stop indicator plate and packing spaceragainst the stem packing.

In this manner the current invention (i) reduces the number of stemassembly components from twelve components of the Jamesbury ball valveto two components (ii) by implementing a single spring loaded nut. Incontrast, the Midland ball valve assembly implements a single locknut toseal a stem packing against the stem during manufacture. However in thisprior art device there is no additional compression device to compensatefor stem packing (i) cold flow and (ii) deterioration after this initialassembly and during subsequent movement of the tank during (iii) largetemperature discrepancies.

The Jamesbury ball valve assembly implements a compression plate andseveral ring devices to compress the stem packing to the stem shaft. Inparticular, the Jamesbury valve also requires a first and second seriesof Bellville washers for additional compression. In contrast, in thecurrent invention the stem packing is compressed along the stem by asingle wave spring during initial manufacture process: This initialsetting by the manufacturer conventionally applies 150 foot-pounds oftorque to the stem lock nut. Thereafter the ball valve assembly isinstalled within the bottom surface of a tank car. The single wavespring provides sufficient additional compression of the stem packingduring time and wear than conventional springs and previously existingstem packing assemblies.

Because of the rotating shaft, wear on the stem packing requiresadditional compression of the stem packing against the stem and theinterior surface of the stem block as time progresses. Otherwise thestem packing will deteriorate within the stem bore and recede from thestem and the interior stem block surface, thereby reducing the sealingability of the stem packing. Without additional spring force compressingthe stem packing, the ball valve assembly is more susceptible to leakagealong the valve stem longitudinal length over time. The currentinvention solves this problem with a single wave spring that (i)continuously compresses the stem packing to the stem and (ii) slows thewear of the stem packing. In the current invention, a single stem locknut is also threaded upon the stem and constrained within the valvebody.

This single stem lock nut forces the wave spring and packing spaceragainst the stem packing. Consequently the current invention comprises anew subassembly that includes the stem packing chevron rings, a singlelock nut and a single wave spring for (i) reduction of stem packingcomponents as well as (ii) an increased operating life of the stempacking materials. During its useful service period the stem packingwears and thereafter conforms to the annular cavity between the stembore and the stem shaft, thereby reducing the sealing ability of thestem packing Without additional spring force compressing the stempacking, the ball valve assembly is more susceptible to leakage alongthe valve stem longitudinal length. In sum, the stem packing assembly isa significant improvement because the presence of a single compressionnut significantly reduces the number of necessary ball valve assemblycomponents.

Consequently the current invention (i) reduces the number of packingcomponents from twelve components of the Jamesbury ball valve to twocomponents (ii) by implementing a single spring loaded nut along withthe wave spring. The Midland ball valve assembly implements a singlelocknut to seal a stem packing against the stem; however, there is noadditional compression device after this initial setting. The Jamesburyball valve assembly implements a compression plate and several ringdevices to compress the stem packing to the stem shaft. In particular,the Jamesbury prototype also requires a first and second series ofBelville washers for additional compression. In sum, the stem packingassembly is a significant improvement because the presence of a singlecompression nut significantly reduces the number of necessary ball valveassembly components.

There are a variety of tank car bottom outlet flange configurations.However the majority of configurations contain (i) a six inch to eightinch orifice (ii) with eight tapped openings along a bolt circle with adiameter of approximately ten and five-eight inches. The flange sealingjoint is either (i) an O-ring held within a groove or (ii) a tongue andgroove with a gasket. The preferred sealing component is a tongue andgroove application for the current invention. The ball valve assembly ofthe current invention and the Midland ball valve assembly need not beremoved from the tank to replace or inspect the internal ball valveassembly components. However the Jamesbury valve assembly has an insertitem on the top of the ball valve assembly by which the internalcomponents are physically accessed only if the ball valve assembly isremoved from the tank.

SUMMARY OF THE INVENTION

The current invention comprises an improved outlet ball valve assemblydesigned to (i) prevent leakage of a liquid from a mobile tank or otherlarge tank-like container (ii) located within the bottom surface of arail car tank or other large tank-like contain. The ball valve assemblyis (i) configured and attached to the tank so the tank bottom openingwithin the tank bottom surface (ii) is continuous for liquid commodityflow through the tank bottom opening and e ball valve assembly (iii)whenever the ball valve assembly is in an open position.

The current invention more particularly comprises an improved bottomoutlet ball valve assembly configured to prevent (i) abrasion of valveassembly components from interior tank commodity contaminants and (ii)damage from corrosive degradation. The improved ball valve assembly alsocomprises solutions for (i) a universal drive coupling (ii) an improvedball component with a single ceramic wiper (iii) improved sealing bystem packing (iii) reduction of stem packing assembly components byimplementing a single wave spring and longitudinal stem groove and (iv)diminished leakage by positioning an O-ring between the ceramic wiperand the body tube of the ball valve assembly.

The current improved bottom outlet ball valve assembly significantlyreduces leakage by implementing (i) an annular rigid ceramic wiper, (ii)a ceramic ball component, and both of which resist scoring, abrasion andchemical exposure corrosion. The ball valve assembly housing preferablycomprises metal and most preferably carbon steel or stainless steel. Theball component for the current ball valve assembly consists entirely andsolely of a ceramic material. Most preferably the ball component ceramicmaterial is made entirely of zirconium oxide, but materials such asaluminum oxide compounds or silicon nitride are also satisfactory. Themost preferred zirconium oxide is also the most cost-effective materialfor the properties it exhibits.

The ball valve assembly body contains additional new or modifiedcomponents such as but not exclusively: wave spring, ceramic wiper, andceramic ball component, drive coupling and stem packing assembly. Seatretainers are preferably (i) made of carbon steel or stainless steel,and (ii) exhibit a fine finish to better contact the ball componentsurface. The seat retainer is preferably bolted to the lower surface ofthe valve body with cap screws. The seat retainer applies mechanicalpressure to the bottom seat against the ball component, thereby creatinga leak tight seal.

The stem is (i) preferably made of stainless steel although morecorrosion resistant metals are also satisfactory and (ii) housed withinthe single body tube. The body tube the ball valve assembly comprises abody tube lateral opening into which the stem is inserted and containedwithin a stem block. This body tube opening continuously (i) comprisesan opening from the exterior surface of the body tube that (ii)simultaneously opens into the interior of the body tube, where (iii) theinterior of the body tube contains the single ball component. The stem(ii) translates the rotation of the opening device, such as handle andadaptor infra, to the ball component within the valve body. The ballcomponent is (i) housed within the valve body (ii) and is preferablycomprised of a ceramic material harder than stainless steel. Forexample, the Vickers hardness measurement for stainless steel is 129,while that measurement is 1150 for zirconium oxide. Similarly, the Knoophardness for stainless steel is 138, while the analogous measurement forzirconium oxide is 1035. The most preferred material is zirconium oxide.

In the current invention, the ball component is vented to prevent liquidentrapment within the valve body, while the ceramic material preventsabrasion of the ball component. The vented ball component does not allowpressure from a liquid commodity to increase between itself and bodytube interior, and which liquid may deform PTFE valve assembly seats[hereinafter ‘seats’]. This deformation occurs in the previouslyexisting devices because back pressure posterior to the ball componentcan dislodge the seats, infra in a downstream direction.

The top seat of the ball valve assembly (i) is housed within the valvebody (ii) preferably made of PTFE and (ii) sits within the upper bodyseat cavity. The top seat is designed to (i) prevent leaks of debris,contaminants and the liquid commodity, and (ii) thereby effectively forma mechanical seal between the ball component, valve body and ceramicwiper. The bottom seat is also preferably (i) made of PTFE (ii) sitswithin the lower seat retainer, and (iii) thereby prevents leaks bycreating a tight mechanical seal between the ball and seat retainer.

The ceramic wiper preferably comprises the same ceramic material as theball component supra. The ceramic wiper is annular in shape and theinterior surface of the wiper has the same radius as the ball component.This ceramic wiper interior surface effectively (i) creates a mechanicaljoint with the exterior surface of the ball component (ii) that preventscontaminant particles from entering the interior of the body tubecontaining the two PTFE seats. In sum, the ceramic wiper sits within theupper body seat cavity where it (i) mechanically seals against the ballcomponent and (ii) prevents contaminants from embedding within, scoring,corroding or otherwise abrading the single top and single bottom seatsrespectively.

Cap screws are preferably made of steel and mechanically attach the seatretainer to the valve body. There are also two 0-rings made of aconventional off the shelf elastomeric material and flouroelastomers.For example when the liquid commodity is ethanol then ethylene propylenediene monomer is the preferred O-ring material. On the other hand, ifwhile if the liquid commodity is crude oil, then a fluorocarbon is themost preferred O-ring material. There is preferably a single upperO-ring located in the upstream portion of the ball valve assemblybetween the ceramic wiper and the valve body. The bottom O-ring islocated in the downstream portion of the ball valve assembly between thelower seat retainer and the valve body. The upper O-ring prevents fluidfrom passing between the horizontal mating surfaces of the ceramic wiperand valve body. The downstream O-ring (i) is located in an annulargroove created between the valve body and seat retainer and (ii) createsa mechanical seal between the valve body and seat retainer. In thecurrent invention O-rings are also round in cross-section.

A thrust washer preferably made of PTFE significantly reduces frictionat the interface between the valve body and stem collar in a manner wellknown in this particular valve industry. The stop pin, preferably madeof steel, allows for a maximum 90 degrees rotation of the ball component(i) within valve body and (ii) between the fully open or closed positionof the ball valve assembly. The stop indicator plate preferably made ofsteel, slides onto the threaded portion of the stem shaft. The stopindicator plate is held rigidly by the square tab upon the plate withinthe stem's horizontal aligned groove.

The current invention also comprises a wave spring, preferably made ofsteel, and this wave spring is positioned between the stem lock nut andstop indicator plate. The wave spring provides additional mechanicalcompression of the stem packing, in addition to the mechanicalcompression of the attached stem lock nut. The stem lock nut, alsopreferably made from steel, provides initial and interim compression ofthe stem packing and retains the stem within the valve.

In the current invention the stem packing preferably (i) comprises abottom packing ring and/or a top packing ring and (ii) is made of PTFE.Between these two rings the stem packing also contains severalintermediate chevrons (U-shaped pattern) PTFE rings that provide a leaktight seal between the stem block and the stem. The packing spacer,preferably made of steel, translates compressive force between the stemlock nut and stem packing into rotational force to move the ballcomponent between a closed or open position. A stem packing assembly isthereby improved because of the single compression nut that results in areduction of stem packing components. With the new stem packing assemblydesign of the current invention a single stem lock nut, thread upon thestem, forces a single wave spring and packing spacer against the stempacking.

In the preferred embodiment the current invention comprises a drivecoupling that is preferably made of steel with (i) the mechanicalconnection to the ball component within the ball valve assembly to (ii)a previously existing square male valve operating device. This operatingdevice rotates the ball component of the ball valve assembly to an openand shut position. The conventional square male valve operating devicemay be, but not exclusively, three-quarters or one-inch square drivetool, ratchet, torque wrench, flex head handle, slinging t-handle orbull handle. The drive coupling of the current invention is preferablythree-quarters inch in square cross section perpendicular to thelongitudinal axis of the drive coupling. With few exceptions, this drivecoupling square drive comprises a universal retrofit to square drivetools and (i) is sufficiently thick in wall thickness so that it doesnot fracture upon application of considerable sudden torque, sustainedtorque, or other twisting forces. The drive coupling may also be usedfor valve assembly handles that are created or produced in the future.

The current drive coupling thereby eliminates the pre-attached handlewith its a strong tendency to (i) swing away from the rail car and (ii)become a safety hazard if it does not otherwise shear from the tank car.In addition to this safety hazard, the invention adaptor eliminates thecost for purchase of ball valve assembly handles that are proprietary tothe handle manufacturer. Pending United States Department ofTransportation require the complete removal of operating handles duringtransit, so the current drive coupling fills an urgent and long feltneed in this industry.

It is therefore a purpose of the present invention to create a ceramicwiper which prevents contaminants from abrading the seats of theinterior of the ball valve assembly.

It is another purpose of the present invention to create a stem assemblythat (i) more efficiently compresses the packing material to the stemand stem bore and (ii) thereby prevents leakage with fewer stem assemblycomponents

It is another purpose of the present invention to (i) provide a drivecoupling that attaches to the valve assembly stem and (ii) retrofitsconventional readily available tools, instead of custom handles, bywhich to open and close the ball valve assembly.

It is another purpose of the current invention to provide a rail cartank bottom fitting ball valve assembly that (i) is economical topurchase (ii) prevents leaks due to wear along the stem (iii) preventsleaks due to abrasion of valve components by tank car contaminants and(iv) prevents leaks due to chemical corrosion of the valve components.

These and other improvements will become increasingly apparent from theattached drawings and the detailed description of the preferredembodiment and other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a partial perspective anterior view of the intactpreferred embodiment of the improved ball valve assembly.

FIG. 1AA is a lateral view of the intact preferred embodiment of FIG.1A.

FIG. 1B is an anterior view of the preferred embodiment of FIG. 1Aattached to the bottom surface of a rail tank car.

FIG. 1BB illustrates an anterior sectional view of the preferredembodiment of FIG. 1A attached to a bottom surface of a rail tank car.

FIG. 2 illustrates an exploded view of the preferred embodiment of theball valve assembly of FIGS. 1A, 1AA.

FIG. 3 illustrates a close partial lateral sectional view of the ballvalve assembly whenever valve body contains welds.

FIG. 4A illustrates a top plan view of the ball valve assembly without adrive coupling.

FIG. 4B illustrates a distal lateral view of the ball valve assemblywithout a drive coupling.

FIG. 4C illustrates a sectional view along line B-B of FIG. 4A.

FIG. 4D illustrates the bottom plan view of the ball valve assembly ofFIGS. 1A, 1AA.

FIG. 5A illustrates an isolated proximal end view of the drive couplingfor the ball valve assembly of FIGS. 1A, 1AA.

FIG. 5B illustrates an isolated lateral view of the drive coupling forthe ball valve assembly of FIGS. 1A, 1AA.

FIG. 5C is an isolated distal view of the drive coupling for the ballvalve assembly of FIGS. 1A, 1AA.

FIG. 6 illustrates an enlarged lateral sectional view of the ball valveassembly of FIGS. 1A, 1AA and 2 without the drive coupling.

FIG. 7A illustrates a close up sectional view of the ceramic wiper andadjacent components of the ball valve assembly of FIG. 2.

FIG. 7B illustrates an isolated upper plan view of the ceramic wiper ofthe ball valve assembly of FIGS. 1A, 1AA.

FIG. 7C is a cross-sectional view of the ceramic wiper along line A-A ofFIG. 7B.

FIG. 7D is an enlarged close up view of FIG. 7C.

FIG. 8A illustrates an isolated upper plan view of the ball component ofthe preferred ball valve assembly of FIGS. 1A, 1AA and 2.

FIG. 8B illustrates a cross-sectional view of ball component along lineA-A of FIG. 8A.

FIG. 9A illustrates an isolated upper plan view of the stem of the ballvalve assembly of FIG. 2.

FIG. 9B illustrates an isolated distal view of the stem of the ballvalve assembly of FIG. 2.

FIG. 9C illustrates an isolated lateral view of the stem of the ballvalve assembly of FIG. 9A rotated 90 degrees.

FIG. 10A illustrates the valve body of FIG. 10B along line A-A.

FIG. 10B illustrates the lateral view of the valve body of the ballvalve assembly.

FIG. 10C illustrates the bottom view for the valve body of FIG. 10B.

FIG. 11A illustrates an upper plan view of an isolated bottom seat ofthe ball valve assembly of FIG. 2.

FIG. 11B illustrates the sectional view along line A-A of the bottomseat of FIG. 11A.

FIG. 12A illustrates an isolated upper plan view of the seat retainer ofthe ball valve assembly of FIG. 2.

FIG. 12B illustrates a sectional view along line A-A of FIG. 12A.

FIG. 13A illustrates an isolated lateral view of the stem block of theball valve assembly of FIG. 2.

FIG. 13B illustrates a view of the stem block along line C-C of FIG.13A.

FIG. 13C illustrates an isolated distal view of the stem block of theball valve assembly of FIG. 2.

FIG. 13C illustrates an isolated distal view of the stem block of theball valve assembly of FIG. 2.

FIG. 14A illustrates an isolated upper plan view of the top flange ofthe ball valve assembly of FIGS. 1A, 1AA and 2.

FIG. 14B illustrates a sectional view along line A-A of FIG. 14A.

FIG. 15A illustrates an upper plan view of the bottom flange for thevalve body for the ball valve assembly of FIG. 2.

FIG. 15B is a sectional view along the first segment of line A-A throughFIG. 15A.

FIG. 15C is a sectional view along the second segment of line A-Athrough FIG. 15A.

FIG. 16A is an upper plan view of the body tube of the ball valveassembly of FIG. 2.

FIG. 16B is a view of the body tube of the ball valve assembly of FIG. 2through the single body tube lateral opening.

FIG. 17A is a top plan view of the top seat for the ball valve assemblyof FIG. 2.

FIG. 17B is a sectional view along line A-A of FIG. 17A.

FIG. 18 is a lower partial sectional enlarged view of the ball valveassembly of FIG. 2.

FIG. 19A is an isolated lateral view of the stem and stop indicatorplate of the ball valve assembly of FIG. 2.

FIG. 19B is an isolated proximal view of the stem and stop indicatorplate of FIG. 19A.

FIG. 19C is an isolated enlarged view of the stem and stop indicatorplate of FIG. 19A rotated 90 degrees.

FIG. 20A is a lateral cross-sectional view of the stem block with stempacking assembly and arrows in the direction of compression by a wavespring.

FIG. 20B illustrates the components in FIG. 20A when the wave springrelaxes and further compresses the stem packing in the direction of thearrow.

FIG. 21 illustrates an enlarged exploded view of the stem, stem packingassembly, drive coupling and square drive tool of the preferredembodiment of FIG. 2.

FIG. 22 illustrates an upper plan view of the ball valve assembly withceramic wiper.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND OTHER EMBODIMENTS

The Preferred Embodiment of Improved Ball Valve Assembly 100

A. Valve Body 1

1. Body Tube 1 c

Referring initially to FIGS. 1A, 1AA, 1B and 1BB, in the preferredembodiment the improved tank bottom outlet ball valve assembly 100[hereinafter ball valve assembly 100] comprises a single sole and onlyvalve body 1. Valve body 1 is preferably made of steel and attaches tobottom surface 300 a of rail car tank 300 or other tank-like container.Valve body 1 can be cast as a single object or otherwise fabricated andassembled; welding 41 is one example in the preferred embodiment. Valvebody 1 is preferably approximately (i) 12.25 inches in total maximumlongitudinal length 1 and (ii) 54.41 inches in maximum diameter. Valvebody 1 comprises a single top flange 27, single bottom flange 25, andsingle body tube 1 c.

Referring to FIGS. 1A, 1AA, 1B, 1BB, 10A, 10B and 10C, 16A and 16B, bodytube 1 c comprises a (i) body tube interior surface 1 f and an exteriorbody tube surface 1 g (ii) as well as a body tube wall thickness 1 ccand (iii) is substantially cylindrical in configuration Body tube 1 chas a single upper body portion 1 h as well as a single lower bodyportion 1 j. Valve body 1 preferably attaches to rail car flange 300 awith bolts 43 in a manner well known in this particular industry. Pleasesee FIGS. 1B, 1Bb and infra. Body tube wall 1 cc (i) is preferably 0.44inch in thickness and (ii) comprises a single lateral body tube opening1 i. Single lateral body tube opening 1 i preferably has a 0.44 radiusof body tube wall 1 cc. Single lateral body tube opening 1 i providesaccess to enclosed ball component 4 by stem 3 through stem block 35.

Body tube 1 c also comprises a (i) single body tube circular uppermostopening 1 m and (ii) single body tube circular lowermost opening 1 t.Body tube circular openings 1 m, 1 t congruently and concentricallyalign with (i) each other (ii) upper and lower flange openings 27 m, 25t respectively and (ii) rail car orifice 300 e (iii) within rail carbottom side 300 a when ball valve assembly is properly assembled andinstalled upon railroad tank car 300. When ball valve assembly 100 isproperly assembled and attached to rail car bottom side 300 a (i) railcar orifice 300 e (ii) top and bottom flange circular openings 27 m, 25t (iii) body tube circular openings 1 m, 1 n and (iv) ball componentbore 4 a form a continuous channel for liquid commodity 200 wheneverball valve assembly 100 is in an open position and configuration.

2. Top Flange 27

Referring to FIGS. 1A, 1AA, 1B, 10A, 10B 10C, 14A and 14B, top flange 27is preferably welded to body tube 1 c at the upper circle body tube edge1 s. However in other embodiments all components of valve assembly 100are cast as a single integral metal piece. Top flange 27 preferably ismade of stainless steel and comprises a finished exterior surface 27 athat is machined to a 125 RMS (where “root means square” defines theroughness of a surface). Top flange 27 is preferably (i) 4.096 inches inminimum interior diameter (ii) twelve and one-quarter inches in maximumexterior diameter (iii) 0.938 inch in minimum thickness and (iv) 0.964inch in maximum thickness. Top flange 27 comprises centrally positionedtop flange opening 27 m.

3. Bottom Flange 25

Referring to FIGS. 1A, 1AA, 1B, 10A, 10B, 10C, 15A, 15B and 15C, bottomflange 25 preferably is made of stainless steel and comprises a finishedexterior surface 25 a machined to a 125 RMS. Bottom flange 25 can be (i)an integral portion of valve body 1 or (ii) welded to body tube 1 c byweld 41 in a manner well known in this industry. Bottom flange 25 ispreferably approximately (i) 6.89 inches in maximum inner diameter (ii)5.90 inches in minimum interior diameter and (iii) 9.0 inches in maximumexterior diameter. Bottom flange (i) has a single centrally positionedbottom flange opening 25 t (ii) that concentrically and congruentlyaligns with upper flange circular opening 27 m as well as body tubecircular openings 1 m, 1 t.

B. Lower Seat Retainer 2

Referring to FIGS. 1BB, 2, 3, 4C, 4D, 12A and 12B, lower seat retainer 2statically presses upon bottom seat 6 to (i) mechanically create a sealagainst leakage of liquid commodity 200 when ball valve assembly 100attaches to railroad tank car 300 or other container 300 b. Lower seatretainer is positioned between and among ball component 4, bottom seat 6and body tube interior surface 1 f. Lower seat retainer 2 comprises asingle (i) maximum exterior retainer diameter 2 d and (ii) maximum innerretainer diameter 2 e. Lower seat retainer 2 is annular and ispreferably (i) four inches in minimum interior diameter (ii) 5.29 inchesin maximum inner diameter (iii) 9.0 inches in maximum exterior diameterand (iv) 1.20 inches in maximum height. Lower seat retainer 2 has anupper retainer surface 2 a and a lower retainer surface 2 b.

As best seen in FIG. 12B, lower seat retainer 2 comprises a seatretainer chamfer 2 c (curved bevel) of (i) preferably 25 degrees along aperpendicular cross sectional line through lower seat retainer 2 and(ii) with a 0.03 radius that (i) flares upward and outward from seatretainer interior surface 2 e. Chamfer 2 c of seat retainer uppersurface 2 p provides a sufficient clearance for ball component 4 torotate in a manner well known in this particular industry. Referring toFIG. 1BB, lower seat retainer 2 (i) continuously contacts lower bodytube interior surface 1 ff and (ii) is preferably machined fromstainless steel and (iii) preferably comprises a serrated spiral finish.Lower seat retainer 2 preferably attaches to valve body 1 with six toeight socket head cap screw 8 within aligned cap screw counter-boreaperture 8 a and 8 aa. Socket head cap screws 8 are (i) preferably madeof steel and (ii) equidistantly spaced from each other in a circularconfiguration. Lower seat retainer 2 is also shaped to reversibly andmechanically receive lower surface 6 b of bottom seat 6 in a flushconfiguration.

C. Bottom Seat 6

Referring to FIGS. 1BB, 2, 3, 4C, 11A, 11B, and 18, bottom seat 6 (i) ispreferably made of PTFE (ii) is positioned between seat retainer 2 andball component 4 infra and (iii) creates a mechanical barrier to leakageof fluid commodity 200 between ball component 4 and seat retainer 2.Bottom seat 6 comprises an upper surface 6 a and a bottom surface 6 b,an exterior surface 6 c and an anterior surface 6 d. Bottom seat 6 isannular in structure and is preferably approximately (i) 4.829 inches inmaximum inner diameter (ii) 4.081 inches in minimum interior diameter(iii) 5.280 inches in maximum exterior diameter and (iv) 0.450 inch inmaximum height 6 h. Bottom seat inner surface 6 d comprises an outwardlyflaring bevel 6 g from bottom surface 6 b at preferably approximately 48degrees from a perpendicular cross-sectional line through bottom seat 6of FIG. 11A.

Bottom seat 6 also comprises a single small seat notch 6 f at theintersection of exterior bottom seat surface 6 c and bottom seat surface6 b. Notch 6 f allows bottom seat surfaces 6 c, 6 b to seal against seatretainer 2 when the seat retainer 2 does not contain perfect corners.Bottom seat exterior surface 6 c is continuously flush with body tubeinterior surface 1 f. Bottom seat 6 preferably comprises (i) acontinuously smooth exterior surface 6 c without grooves, otherindentations or other structural features so (ii) bottom seat 6 moreeffectively maintains continuous flush contact with seat retainerinterior surface 2 f.

D. Ball Component 4

Referring to FIGS. 1BB, 2, 3, 4, 8A and 8B, continuously contacting bodytube interior surface 1 f, bottom seat 6 and upper seat 5 is ballcomponent 4. Ball component 4 is made of a ceramic material 4 f, mostpreferably zirconium oxide although zinc oxide and aluminum oxide arealso satisfactory. The first and second most preferred zirconium oxidematerials 4 ff, 4 fff respectively are each five to seven times harderthan stainless steel. The first most preferred zirconium oxide material4 ff also exhibits the following mechanical properties: Hardness HV5(Vickers) 1650 kg/mm2; tensile strength 70 kpsi and; thermal expansion25-200 C 8.50E-06. The second most preferred zirconium oxide material 4fff exhibits the following mechanical properties: Hardness HV5 1150kg/mm2; tensile strength 85 kpsi and; thermal expansion 25-200 C9.90E-06.

Ball component 4 is preferably six inches in diameter. Ball component 4has a single continuous ball cylindrical bore 4 a that is preferably (i)positioned along a ball longitudinal line 4 e through the center of ballcomponent 4 and (ii) four inches in diameter. Ball cylindrical bore 4 ais continuous and (i) opens outwardly along exterior Ball surface 4 d atfirst and second ball openings 4 x, 4 y respectively and (ii) ballopenings 4 x, 4 y are preferably 180 degrees apart from each other. Inan open position, ball openings 4 x, 4 y (i) congruently andconcentrically align with aligned flange openings 27 m, 25 t, body tubeopenings 1 m, 1 t and railroad tank car orifice 300 e (ii) when ballvalve assembly 100 is properly assembled and attached to lower railroadcar tank surface 300 a. In this configuration ball cylindrical bore 4 ais the channel through which liquid commodity 200[not seen] flowswhenever ball valve assembly 100 is open.

Referring to FIGS. 8A and 8B, ball component 4 comprises ball vent 4 j,and ball vent aperture 4 j is preferably (i) one-fourth inch in lengthand (ii) one-eighth inch in diameter. Ball vent aperture 4 j is locatedproximal to, and is continuous with, ball component recess 4 b and ballcylindrical bore 4 a. Vent 4 j prevents entrapment of contaminateswithin valve body 1 while ball component ceramic material 4 f preventsscoring of ball component exterior surface 4 d. As best seen in FIGS. 4Cand 8A, stem proximal curved end 3 n infra tightly lodges within ballcomponent recess 4 b. As best seen in FIGS. 8A and 8B, there ispreferably 0.25 inch of ceramic material 4 f between ball recess 4 b andball cylindrical bore surface 4 aa.

E. Top Seat 5

Referring to FIGS. 1BB, 2, 3, 4C, 17A and 17B, top seat 5 is preferably(i) made of PTFE and (ii) positioned within body tube interior 1 aa atupper body tube wall 67. Top seat 5 is positioned between, and is incontinuous contact with, ball component 4 and body tube interior surface1 f. Top seat 5 is preferably (i) annular in structure (ii) 5.140 inchesin maximum interior diameter (iii) 5.628 inches in maximum outerdiameter and (iv) 0.450 inch in maximum thickness. Top seat 5 has anupper top surface 5 a and a lower top surface 5 b. Top seat 5 also hasan exterior upper seat annular surface 5 c and an interior upper seatannular surface 5 d.

As best seen in FIGS. 17A and 17B, top seat 5 comprises an upper seatbevel 5 g. Upper seat bevel 5 g flares (i) upwardly and outwardly frombottommost surface 5 b to uppermost surface 5 a (ii) at an angle ofpreferably 54 degrees from a perpendicular cross section of top seat 5of FIG. 5A. Top seat 5 also comprises a single small continuous chamfer5 gg (i) at the bottom of upper seat bevel 5 g along top lower seatsurface 5 b (ii) with a radius of preferably 0.03. Top seat 5mechanically provides a seal to prevent leaks of liquid commodity 200between and among ball component 4, valve body 1 and ceramic wiper 7infra. Top seat 5 preferably comprises (i) a continuously smoothexterior surface 5 c without grooves, other indentations or otherstructural features (ii) so seat 5 more effectively maintains continuousflush contact with body tube interior surface 1 f.

F. Ceramic Wiper 7

Referring to FIGS. 1BB, 3, 4, 7A, 7B and 7C, ceramic wiper 7 is anannular component consisting entirely of a ceramic material five toseven times harder than stainless steel. Ceramic wiper 7 is positioned(i) within upper tube body interior 1 aa and (ii) between top seat 5 andO-ring 9 a infra. The preferred materials for ceramic wiper 7 arealuminum oxide, zirconium oxide and zinc oxide. Most preferably ceramicwiper is made of zirconium oxide with the identical macro materialcharacteristics as the most preferred zirconium oxide of ball component4 supra. Ceramic wiper 7 has an upper wiper surface 7 b and a lowerwiper surface 7 a, an exterior wiper surface 7 c and an interior wipersurface 7 d. Ceramic wiper 7 is preferably approximately (i) 4.056inches in minimum interior diameter (ii) 4.391 inches in maximuminterior diameter (iii) 5.628 inches in maximum exterior diameter and(iv) 0.250 inch in thickness.

As best seen in FIGS. 7B, 7C and 7D, ceramic wiper 7 preferablycomprises a single wiper circular chamfer 7 f that (i) opens upwardlyand outwardly to upper wiper surface 7 b from wiper interior surface 7 dand lower ceramic wiper surface 7 a (ii) at an angle of preferably 45degrees from perpendicular cross section of the ceramic wiper 7 of FIG.7B (iii) with radius 3.00 and (iv) 0.036 inch in height. Ceramic wiper 7also contains (i) a single continuous lower circular wiper bevel 7 h atlower wiper surface 7 a and (ii) a single continuous circular upperwiper bevel 7 m at upper wiper surface 7 b. Continuous circular wiperbevels 7 h, 7 m are each continuous with single circular continuouswiper chamfer 7 f. Lower continuous circular wiper bevel 7 h ispreferably (i) 0.143 inch in length (ii) 0.047 inch in depth and (iii)forms an angle of 72 degrees with perpendicular cross section of theceramic wiper 7 of FIG. 7B. Upper continuous circular wiper bevel 7 m ispreferably (i) 0.02 inch in length (ii) 0.036 inch in depth and (iii)forms an angle of 29 degrees with perpendicular cross-section of theceramic wiper 7 of FIG. 7B.

Referring to FIGS. 7A, 7B, 7C and 7D, ceramic wiper 7 also comprises asingle continuous smooth circular wiper groove 7 e that is preferably(i) 0.077 inch in depth (ii) 0.145 inch in width and (iii) 16.93 inchesin interior circumference along exterior wiper surface 7 c. Smoothcontinuous wiper circular groove 7 e is located at the intersection ofceramic wiper upper surface 7 b and exterior ceramic wiper surface 7 c.When ball valve assembly 100 is properly assembled, smooth continuouswiper circular groove 7 e is continuous and contiguous with continuousupper flange circular groove 27 k, to form continuous smooth upperO-ring circular notch 1 q. Continuous smooth upper O-ring circular notch1 q contains upper O-ring 9 a whenever ball valve assembly 100 isproperly assembled.

Whenever ball valve assembly 100 is properly assembled, ceramic wiperchamfer 7 f mechanically prevents contaminants within liquid commodity200 and tank interior from (i) by-passing ball component 4 and (ii)thereby embedding within top seat 5 and/or bottom seat 6. Wiper bevels 7h, 7 b are configured so ceramic wiper 7 is less susceptible to chippingalong upper wiper surface 7 b and lower wiper surface 7 a. Wiper bevels7 h; 7 m and wiper chamfer 7 f are also configured to push particlesfrom seats 5, 6 whenever ball component rotates. Ceramic wiper 7 (i)must withstand the impact of abrasive contaminants over a protractedtime period and (ii) therefore wiper 7 must be harder than thesecontaminant particles. Ceramic wiper 7 must also be positioned upstreamwithin upper body tube interior 1 aa to protect top seat 5.

Interior ceramic wiper surface 4 d forms a continuous mating surfacewith ball component exterior surface 7 d. This spherical interior matingsurface comprising wiper bevel 7 f, wiper chamfer 7 h and wiper chamfer7 m (i) completely conforms to ball component radius 4 e, and (ii)thereby creates a continuous mechanical joint that prevents particulatematerial from entering body tube interior 1 aa containing seats 5, 6.Ceramic wiper 7 is held in place by ball component 4, so ceramic wiper 7(i) is in mobile scraping contact with exterior ball component surface 7d and (ii) thereby traps abrasive and corrosive contaminants.

G. Body O-Rings 9 a, 9 b

Referring to FIGS. 2, 4C, 6, 7A and 18, ball valve assembly 100comprises single sole and only upstream body O-ring 9 a and single soleand only downstream body O-ring 9 b. Each body O-ring 9 a, 9 b ispreferably identical in width to the other with a smooth surface anduniform cross-sectional diameter. Body O-ring 9 a preferably has (i) aninner diameter of 5.487 inches (ii) a cross-sectional diameter of 0.103inch and (iii) an exterior diameter of 5.693 inches. Body O-ring 9 bpreferably has (i) an inner diameter of 6.487 inches (ii) across-sectional diameter of 0.103 inch and (iii) an exterior diameter of6.693 inches. When ball valve assembly is properly assembled, upstreambody O-ring 9 a is preferably located within (i) lower continuouscircular wiper groove 7 e and (ii) continuous body tube circularinterior groove 27 k (iii) to form continuous circular wiper notch 1 q.Please see FIG. 7A. Upstream body O-ring 9 a provides a mechanicalbarrier to leakage of liquid commodity 200 between and among ceramicwiper 7, valve body 1 and top seat 5.

Referring to FIGS. 1BB, 2, 4C, 6 and 18, downstream body O-ring 9 b islocated within continuous lower body tube circular groove 1 o along bodytube interior surface 1 f. Continuous lower body tube circular groove 1o is preferably approximately (i) 0.145 inch in depth (ii) 0.145 inchesin width and (iii) 17.25 inches in interior circumference along bodytube interior surface 1 f. Downstream body O-ring 9 b creates amechanical barrier that prevents leakage of liquid commodity 200 betweenseat retainer 2 and valve body 1.

H. Stem Block 35

Referring to FIGS. 1BB, 3, 13A, 13B and 13C, stem block 35 comprises anintegral solid component that is (i) positioned adjacent to body tube 1c and (ii) preferably made of steel. Stem block 35 can (i) comprisewelds 41 to body tube 1 c or (ii) be cast as an integral portion ofvalve body 1. Stem block 35 (i) is preferably partially rectangular inshape in perpendicular cross-section to stem block longitudinal axis 35c. Stem block 35 has a proximal stem block end 35 a and a distal stemblock end 35 b. Stem block 35 is preferably (i) 2.195 inches in maximumlongitudinal length 112 (ii) 2.92 inches in maximum height h5 and (iii)2.16 inches in maximum depth d3. At stem block distal end 35 b, stemblock 35 comprises stop pin aperture 11 a into which stop pin 11 insertswhenever ball valve assembly 100 is properly assembled.

Referring to FIGS. 13A, 13B and 13C, stem block 35 comprises a singlestem block longitudinal cavity 35 d that mechanically confines stem 3,stem packing 15 and packing spacer 16 whenever ball valve assembly 100is properly assembled. Stem block longitudinal cavity 35 d comprises acontinuous rigid smooth interior longitudinal stem block cavity wall 35i that is (i) preferably completely smooth and (ii) shaped to conformto, and be slightly wider in cross-section diameter than, stem 3, stempacking 15 and packing spacer 16 within stem block longitudinal cavity35 d. Stem block interior longitudinal cavity 35 d comprises a proximalstem block cavity 35 f, a median stem block cavity 35 g and a distalstem block cavity 35 h. Medial stem block cavity 35 g is preferably (i)0.772 inch in longitudinal length and (ii) 1.274 inches in diameter.Proximal stem block cavity 35 f is preferably (i) 0.277 inch inlongitudinal length and (ii) 1.774 inches in diameter, while distal stemblock cavity 35 h is preferably (i) 1.21 inches in longitudinal lengthand (ii) 1.774 inches in diameter.

I. Stem 3

Referring to FIGS. 1A, 1BB, 2, 3, 4A, 4B, 4C, 4D, 6, 9A, 9B, 9C, 19A,19B and 19C, stem 3 is (i) preferably an integral partially cylindricalrigid solid that is machined from steel and (ii) positioned within stemblock 35 so longitudinal stem axis 3 c is superimposed upon stem blocklongitudinal cavity axis 35 c (iii) whenever ball valve assembly 100 isproperly assembled. Stem 3 is preferably (i) 4.393 inches in maximumlongitudinal length 3 j and (ii) 1.75 inches in maximum diameter. Stem 3has a single proximal stem end 3 a and a single distal stem end 3 b.Stem block longitudinal axis 35 c and superimposed longitudinal stemaxis 3 c are (i) straight, linear (ii) perpendicular to ball componentrecess posterior wall 4 k and (iii) positioned at center point 4 k ofball recess posterior wall 4 k and (iv) in parallel alignment with ballcomponent lateral recess wall 4 p (v) whenever ball valve assembly 100is properly assembled. Stem 3 also comprises stem screw aperture 3 x,and screw 34 reversibly inserts into stem screw aperture 3 x in aproperly assembled ball valve assembly 100.

As best seen in FIGS. 9A, 9C, 19A and 19C, stem 3 comprises (i) a singlecylindrical medial threaded longitudinal stem segment 3 m with threading3 mm along exterior stem surface 3 e (ii) a single proximal smoothcylindrical solid longitudinal segment 3 g with a smooth exterior stemsurface 3 gg and (iii) a smooth single distal longitudinal segment 3 qthat is square in cross-section perpendicular to stem longitudinal axis3 c. Each longitudinal stem segment 3 g, 3 q is preferably contiguous,continuous and integral with longitudinal stem segment 3 m. As best seenin FIGS. 9A and 9C, half-disc shaped protuberance 3 n (i) forms proximalstem end 3 a and (ii) is preferably shaped as a quarter-sphere in aconfiguration well known in this particular industry. Half-disc shapedprotuberance 3 n preferably comprises a radius of 1.375 alongprotuberance exterior curved surface 3 nn.

Half-disc shaped protuberance curved surface 3 nn (i) inserts withinball component recess 4 b and (ii) is mechanically retained therein by acontinuous tight fit within ball component recess interior rigid surface4 b. Please see FIGS. 8A and 8B. Half-disc shaped protuberance 3 n isproximal to smooth solid proximal cylindrical longitudinal segment 3 g.Proximal cylindrical longitudinal segment 3 g is (i) integrallycontinuous with medial threaded longitudinal stem segment 3 m (ii)located proximal to medial threaded longitudinal stem segment 3 m (iii)3.275 inches in longitudinal length and (iv) 1.250 inches diameter.Medial threaded longitudinal stem segment 3 m is preferably (i) 1.28inches in longitudinal length and (ii) 1.25 inches in a cross-sectionaldiameter perpendicular to stem longitudinal axis 3 c.

Integrally connected to medial threaded longitudinal stem segment 3 m iscontinuous distal longitudinal stem segment 3 q with smooth continuousdistal exterior stem segment surface 3 qq. Referring to FIGS. 9A, 9B,9C, 19A, 19B and 19C, distal longitudinal stem segment 3 q is preferably(i) one and one-quarter inches in longitudinal length 110 and (ii) 0.875inch on each side in square cross-section diameter perpendicular tolongitudinal stem axis Cl. Distal stem longitudinal segment 3 qcomprises distal stem longitudinal segment bore 3 z, and bore 3 z ispreferably centrally positioned along stem longitudinal segment 3 c.

Distal stem longitudinal segment bore 3 z also congruently aligns with,and is superimposed upon, stem longitudinal stem axis 3 c. Distal stemlongitudinal segment bore 3 z preferably comprises (i) a smooth interiorbore wall surface 3 zz and (i) four rounded stem bore edges 3 l, 3 m, 3n, 3 o in cross section perpendicular to stem longitudinal axis 3 c.Each rounded stem bore edge 3 l, 3 p, 3 o and 3 r has a correspondingradius of preferably 0.09. Distal longitudinal stem segment 3 q is theportion of stem 3 (i) into which drive coupling proximal segment end 17a inserts infra.

As best illustrated in FIGS. 9A, 9B, 9C, 19A, 19B and 19C, distallongitudinal stem segment 3 q contains a single set screw stem aperture3 x. Set screw stem aperture 3 x is preferably (i) perpendicular to stemlongitudinal axis 3 c and (ii) 0.478 inches from stem distal end 3 b.Set screw stem aperture 3 x has a (i) first set screw stem apertureopening 3 y and (ii) second set screw aperture opening 3 yy. Set screwaperture openings 3 y, 3 yy directly oppose each other at 180 degreesalong exterior stem surface 3 qq of distal stem segment 3 q. Wheneverset screw stem aperture 3 x concentrically aligns with drive couplingscrew aperture 17 e infra, a single set screw 34 can reversibly insertand thereby mechanically attach stem 3 to drive coupling 17.

As best illustrated in FIGS. 9C and 19C, longitudinal stem groove 3 d(i) is parallel to stem longitudinal axis 3 c and (ii) is preferablymachined into exterior threaded surface 3 e of medial stem segment 3 m.Longitudinal stem groove 3 d reversibly and mechanically engagesindicator plate tab 50 whenever ball valve assembly is properlyassembled. Please see FIG. 21. Longitudinal stem groove 3 d has a rigidcontinuous smooth interior surface 3 s preferably consisting of (i) twoperpendicular stem groove rigid side walls 3 t, 3 tt and (ii) a singlerigid flat bottom surface 3 dd. Longitudinal system groove 3 d ispreferably (i) 1.08 inches in longitudinal length (iii) 0.189 inch inwidth and (ii) 0.188 inch in depth.

Stem 3 translates rotation of prior art opening tool 20, generally ahandle 20 b to ball component 4 through the above described mechanicalattachment at ball component recess 4 b. As best seen in FIG. 8A, stem 3mechanically connects to ball component 4 at proximal stem end 3 a bymating half-disc curved exterior surface 3 nn with ball recess surface 4bb in a contiguous manner well known in the industry.

J. Thrust Washer 10 and Stop Pin 11

Referring to FIGS. 2, 4C and 21, thrust washer 10 (i) is preferably madeof PTFE and (ii) provides a substantially reduced friction interfacebetween valve body 1 and machined stem collar 3 i. Thrust washer 10 ispreferably approximately (i) 1.774 inches in exterior diameter (ii)1.274 inch in interior diameter and (iii) one-sixteenth inch inthickness. Stop pin 11 is preferably (i) made of steel and (ii) providesa 90 degree rotation of ball component 4 to a fully open or closedposition in a well known manner. Stop pin 11 is preferably approximately(i) three-eighths inch in diameter and (ii) one and one-quarter inchesin length.

K. Stop Indicator Plate 12

Referring to FIGS. 2, 4C, 6 and 21, stop indicator plate 12 ispreferably (i) made of steel and (ii) positioned in a directionperpendicular to and along threaded longitudinal axis 3 a of threadedstem segment 3 m. Stop indicator plate 12 is preferably (i) maintainedaxially along threaded segment 3 mm by square indicator tab 50respectively and (ii) preferably square tab 50 is an integral structuralfeature of stop indicator plate 12 (iii) where square tab 50 insertswithin stem longitudinal slot 3 d. Stop indicator plate 12 (i) restrictsstem rotation to a maximum of ninety degrees and (ii) provides a visualindication of an open or closed valve position to operating personnel ina well known manner.

L. Wave Spring 13

Referring to FIGS. 2, 3, 4C, 20A, 20B and 21, wave spring 13 is (i)preferably made of stainless steel with the following mechanicalproperties (i) Tensile strength UTS, ksi (MPa) 1517 and (ii) Hardness(Rockwell) C43. This specific stainless steel is also particularlycorrosion resistant, but carbon steel is also satisfactory. Wave spring13 is (ii) located between packing spacer 16 and stop indicator plate 12and (iii) oriented in a direction perpendicular to stem longitudinalaxis 3 c whenever ball valve assembly 100 is properly assembled. Wavespring 13 preferably (i) is 1.34 inches in inner diameter (ii) 0.018inch in strip thickness (iii) comprises four turns and (iv) comprisesshim ends. Wave spring 13 provides mechanical compression to stopindicator plate 12, as well to packing spacer 16 and stem packing 15 toin addition to compression of stem lock nut 14 infra.

As time and wear from use in a mobile container increase in previouslyexisting devices, stem packing 15 diminishes in volume and density. As aresult an excessive physical clearance develops between stem block 35and stem 3, and this clearance becomes a channel for liquid commodityleakage from body tube 1 c. In contrast, with the current invention ballvalve assembly 100 is initially assembled by the manufacturer with amaximally compressed wave spring 13. Please see FIGS. 20A and 20B. Thiscompression results in an initial maximum elastic potential energy xx1within wave spring 13 while wave spring 13 presses against packingspacer 16 and stop indicator plate 12.

As a result, over the effective life time of valve assembly 100 (i) wavespring 13 gradually releases elastic potential energy xx2 as pressureagainst receding stem packing 15 (ii) in the direction of the arrow inFIGS. 20A and 20B. This released energy results in wave spring 13expansions and spring 13 physically presses upon stem packing 15. Uponpressure, stem packing 15 reconfigures to a smaller and denser volume.Wave spring 13 thereby prevents (i) an excessive physical clearance fromdeveloping between stem 3 and stem packing 15 (ii) while stem packing 15is simultaneously compressed into a denser, leak proof material.

M. Packing Spacer 16

As best illustrated in FIGS. 4, 20A, 20B and 21, packing spacer 16 ispreferably a single integral solid stainless steel component, and thisstainless steel most preferably exhibits the following mechanicalproperties: (i) 0/2% YSKsi (MPa) 42 (290) and (ii) hardness (Rockwell)B82. However, packing spacer 16 may also be made of carbon steel.Packing spacer 16 is an annular tube-like component positioned between(i) stem packing 15 and (ii) stop indicator plate 12 and (iii) alongstem longitudinal axis 3 a (iv) in a perpendicular orientation tolongitudinal stem axis 3 a. Packing spacer 16 most preferably consistsof stainless steel and is preferably (i) 1.265 inches in interiordiameter (ii) 1.76 inches in exterior diameter and (iii) 0.75 inch inlongitudinal length.

N. Stem Packing 15

Referring to FIGS. 2,4C, 20A, 20B and 21, stem packing 15 is (i)preferably made of PTFE (ii) mechanically confined within longitudinalstem bore 3 h and (iii) continuously compressed upon stem exteriorsurface 3 e. Stem packing 15 preferably consists of several chevronrings 65 a, 65, 65 b that align (i) perpendicular to stem longitudinalaxis 3 c and (ii) concentrically with each other. Each chevron ring 65a, 65, 65 b is preferably approximately (i) 1.25 inches in innerdiameter (ii) 1.75 inches in outer diameter and (iii) 13/16 inch inthickness.

Stem packing 15 most preferably comprises (i) a single convex proximalchevron ring 65 a and (ii) a single distal concave chevron ring 65 b(iii) with a total of three to four interior chevron rings 65. Eachproximal convex chevron ring 65 and distal chevron ring 65 a, 65 brespectively confines intermediate chevron rings 65. Each convex chevronring 65 a or 65 fits within the single concave face 65 c of adjacentchevron ring 65 b or 65 as the case may be. Each individual chevron ring65 a, 65, 65 b provides a tight mechanical seal with (i) stemlongitudinal cavity wall 3 z and (ii) stem exterior surface 3 e toprevent leakage of liquid commodity 200 between valve body 1 and stem 3.

Referring to FIGS. 4C, 6, 20A and 20B, stem packing 15 is confinedwithin longitudinal cylindrical stem bore interior surface 3 z, stemexterior surface 3 e, and packing spacer proximal surface 16 a. Stempacking 15 is continuously mechanically compressed upon stem exteriorsurface 3 e by longitudinal cylindrical bore interior surface 3 z,indicator plate 12, wave spring 13 and stem lock nut 14. During rotationstem packing 15 experiences wear from continuous frictional andmechanical contact with stem rotating exterior surface 3 e. In addition,PTFE of valve assembly interior components, such as stem packing 15,will cold flow between stem 3 and valve body 1, as well as between andamong packing spacer 16, valve body 1 and stem 3. Furthermore, theclearance between rotating stem 3 and stem packing 15 becomesincreasingly physically inconsistent and uneven as stem packing 15deforms. Consequently stem packing assembly components are no longeraligned perpendicular to the longitudinal stem axis 3 and thereby resultin additional wear to rotating stem 3.

In the current industry, stem packing 15 and stem spacer 16 are machinedto as close a tolerance to stem 3 as is technically possible when a ballvalve assembly is initially manufactured. Nevertheless, stem packing 15and stem spacer 16 rotation clearances must exist for stem 3 to operate.Because of this clearance requirement and inevitable wear, packingspacer 16 must be further compressed to stem 3 to provide an adequateseal. Without wave spring 13, there is loss of mechanical compressionand leakage of liquid commodity 200 within stem packing 15. This isbecause an initially compressed wave spring 13 exerts force upon packingspacer 16 and stem assembly 15 (i) over a protracted operating timeperiod (ii) in the direction indicated by arrows in FIGS. 20A and 20B.In contrast to the disc springs in previously existing valve assemblies,wave spring 13 does not require a diameter so wide that the diameterdimension prevents appropriate operation of stem 3.

Upon commencing of ball valve assembly 100 operation, stem packing 15immediately undergoes the above described wear, as well as temperature‘swing’ deterioration, of the mobile application of the ball valveassembly 100. Because of these temperature variations, friction andother wear, stem packing 15 diminishes in density, dimensions, andbecomes increasingly damaged over prolonged time and use. To counteractthis inevitable damage, elastic potential energy stored in compressedwave spring 13 is increasing exerted as pressure upon stem packing 1 inthe direction of the respectively arrows in FIGS. 20A and 20B.Compressed wave spring 13 is increasing decompressed during this processand the released potential energy thereby maintains stem packing (i) atan appropriate density and (ii) adjacent to stem exterior surface 3 eand stem bore interior wall surface 3 z while (iii) maintaining therequired clearance. As a result of this compression, stem packing 15also becomes shorter in stem packing longitudinal length 15 c. However,as wave spring gradually expands longitudinally over time, thisdiscrepancy in stem packing longitudinal length is replaced by expandedwave spring longitudinal length.

Referring to FIGS. 2, 3, 4B and 21, threaded stem lock nut 14 ispreferably (i) comprised of zinc plated steel and (ii) encircles andengages threaded medial stem section 1 m. Stem lock nut 14 providesinitial and interim compression for stem packing 15 and (iii) retainsstem 3 within ball valve assembly 100.

O. Drive Coupling 17

Referring to FIGS. 1A, 1AA, 1B, 1BB, 2, 3, 5A, 5B, 5C and 21, drivecoupling 17 is preferably made of carbon steel. Drive coupling 17 has asingle proximal drive coupling end 17 a and a single distal drivecoupling end 17 b. Drive coupling 17 is preferably (i) 1.75 inches intotal longitudinal length 14 and (ii) 1.75 inches in diameter d21 ofperpendicular cross-section d22. Drive coupling 17 contains a singlecontinuous drive coupling longitudinal channel 17 f superimposed alonglinear drive coupling linear longitudinal axis 17 i. Drive couplinglongitudinal channel 17 f is also centrally positioned within drivecoupling 17 along drive coupling longitudinal axis 17 i. Drive couplinglongitudinal channel 17 f has a continuous smooth interior drivecoupling wall 17 ff.

Referring to FIGS. 5A, 5B and 5C, drive coupling longitudinal channel 17f preferably comprises (i) a single larger proximal drive couplingchannel segment 17 g and (9 ii) a smaller distal drive coupling channelsegment 17 h. Larger proximal drive coupling channel segment 17 g ispreferably (i) square in cross-sectional shape perpendicular to drivecoupling longitudinal center line 17 i (ii) with round corners 17 m, 17n, 17 o and 17 p. Larger proximal drive coupling segment 17 g ispreferably (i) 0.890 to 0.895 inch in length 110 along each square side17 k (iii) 0.88 inch in longitudinal length 111 and (ii) preferably hasa radius of curvature of each rounded corner 17 m, 17 n, 17 o, 17 p of0.09. Larger proximal drive coupling channel segment 17 g also comprisesa single socket stem screw aperture 17 e.

As best seen in FIG. 3, a drive coupling socket stem screw 34 canpenetrate congruently and concentrically aligned (i) drive couplingaperture 17 e and (ii) distal stem segment aperture 3 x (iii) in adirection perpendicular to drive coupling longitudinal axis 17 i. Drivecoupling socket set crew 34 is preferably (i) made of alloy steel suchas stainless steel and (i) a self locking socket set screw. Drivecoupling socket set screw 34 is preferably approximately (i) 5/16 inchin diameter (ii) one inch in longitudinal length.

Whenever drive coupling socket set screw 34 is inserted, screw 34 ispreferably initially coated with a heated liquid nylon material that isstandard in the industry for this purpose. As best seen in FIGS. 1A and21 (i) whenever larger longitudinal drive coupling channel segment 17 gencompasses distal stem segment 3 q, (ii) drive coupling set screw 34inserts into distal stem end segment 1 q through concentrically andcongruently aligned distal stem aperture 3 x and drive coupling aperture17 e (iii) thereby mechanically connecting stem distal end 3 b to drivecoupling proximal end 17 a.

Referring to FIGS. 5B and 5C, continuous with and distal to largerlongitudinal channel segment 17 d is a single smaller drive couplinglongitudinal channel segment 17 h at distal drive coupling end 17 b.Smaller drive coupling longitudinal channel segment 17 h is preferably(i) square in perpendicular cross-section to drive coupling channellongitudinal axis 17 i and (ii) 0.753 to 0.758 inch on eachcross-sectional square side 17 k. Smaller drive coupling longitudinalchannel segment 17 h also comprises four continuous rounded corners 17r, 17 s, 17 t, 17 u (i) in perpendicular cross-section to drive couplinglongitudinal axis 17 i and (ii) each corner 17 r, 17 s, 17 t, 17 upreferably has a corresponding radius 0.06.

Referring to FIG. 21, drive coupling 17 can attach simultaneously to (i)distal square stem end 3 b at proximal drive coupling end 17 a and (ii)proximal square drive tool end 20 a at distal drive coupling end 17 b.Smaller distal drive coupling longitudinal channel segment 17 h snuglymechanically and reversibly receives (i) proximal square drive tool end20 a of most of the group consisting of square drive tools 20 (ii) toretain drive coupling 17 to square drive tool 20. Simultaneously largerproximal drive coupling longitudinal channel segment 17 g mechanicallyand reversibly inserts into stem distal longitudinal segment 3 q.

Referring to FIGS. 1BB and 21, drive coupling proximal larger channelsegment 17 g slides over distal stem segment 3 q where segment 17 g ismechanically and reversibly secured by (i) socket stem screw 34.Proximal square drive tool end 20 a snugly, mechanically and reversiblyinserts into distal drive coupling longitudinal channel segment 17 h tooperatively rotate stem 3. Whenever a square drive tool such as squaredrive tool 20 or 20 c is operatively attached to stem 3, stem 3 willrotate ball component 4 through a maximum of 90 degrees to an open orclosed position by stem mechanical engagement with ball component recess4 b. Conventional square drive tool 20 or 20 c can be, but notexclusively, a ratchet, torque wrench, flex head handle, slidingt-handle or bull handle.

Drive coupling 17 eliminates leakage and discharge events associatedwith permanently attached conventional handles 20, because it eliminatespre-attached square drive tools with handles 20 during operation. As aresult, during a hazardous incident there is no pre-attached squaredrive tool (i) to unintentionally shear from and thereby open ball valveassembly 100 (ii) with a resulting torrent of liquid component 200 intothe environment. Drive coupling is a component of the preferredembodiment of improved ball valve assembly 100. However, in otherembodiments ball valve assembly 100 is also operational when (i)attached to a wrench and (ii) drive coupling 17 is absent.

II. Assembly of Bottom Outlet Ball Valve Assembly 100

As best illustrated in FIG. 1B, ball valve assembly 100 is assembled asfollows:

1. Body tube 1 c is placed upside down on a suitable fixture.

2. The operator next (i) places thrust washer 10 onto stem proximal tostem distal end 3 b and (ii) thereafter pushes thrust washer 10 ontostem 3 until thrust washer 10 seats against stem collar 3 i. FIGS. 2 and21.

3. The operator next inserts stem 3 into tube body uppermost opening 1 minto body tube interior 1 aa, and then through body tube lateral opening1 i. FIGS. 1A and 2.

4. The operator next installs stem packing 15 (i) longitudinally alongstem 3 (ii) while stem 3 protrudes from body tube lateral opening 1 ithrough stem block longitudinal cavity 35 d as follows:

-   -   (i) Proximal convex chevron ring 65 a with concave chevron        surface 65 aa facing proximally towards proximal stem end 3 a;    -   (ii) Distal chevron ring 65 b and intervening chevron rings 65        that fit within corresponding chevron concave surfaces 65 aa.        FIGS. 20A and 20B;    -   (iii) Thereafter the operator presses chevron rings 65 a, 65, 65        b into stem block longitudinal cavity 35 h. FIG. 6, 20B.        5. The operator next inserts packing spacer 16 into stem block        continuous longitudinal cavity 35 d, so packing spacer 16 is        positioned distal to distal chevron ring 65 b, as seen in FIGS.        20A and 20B.        6. The operator next (i) inserts stop indicator plate 12 onto        stem 3 (ii) with any opening and closing written instructions        upon stop indicator plate surface 12 b facing away from body        tube 1 c. FIG. 21.        7. The operator next positions wave spring 13 over and onto stem        3 immediately adjacent and distal to stop indicator plate 12.        FIGS. 20A, 20B and 21.        8. The operator next (i) positions stem lock nut 14 over and        onto stem 3 adjacent and distal to wave spring 13 (ii) where        stem lock nut 14 engages stem exterior threads 33 m. By rotating        stem lock nut 14 along stem threading 1 mm, the operator then        torques nut 14 to preferably 150 foot pounds. FIG. 21.        9. The operator next inserts proximal larger drive coupling bore        segment 17 g into distal stem segment 3 q so drive coupling        aperture 17 e congruently aligns with distal stem segment        aperture 3 x. He or she then threads set screw 34 into both        concentrically aligned apertures 3 x, 17 e to mechanically        attach drive coupling 17 to stem distal longitudinal segment 3        q. FIGS. 1A, 1BB, 21.        10. The operator thereafter places uppermost body O-ring 9 a        into uppermost corner 67 of body tube interior surface 1 f. FIG.        1BB, 4C.        11. The operator next inserts ceramic wiper 7 through upper body        tube opening 1 m and upper flange opening 27 m into body tube        interior 1 aa so (i) uppermost body O-ring 9 a is snugly wedged        within upper O-ring notch 9 c and (ii) where upper O-ring notch        9 c is created by adjacent body tube groove 1 q and ceramic        wiper groove 7 e (iii) and ceramic wiper groove 7 e is formed by        wiper short sides 7 ee and 7 eee. Wiper short sides 7 ee and 7        eee are rigid, smooth and perpendicular to each other. FIGS. 7A,        7C and 7D.        12. The operator next (i) places top seat 5 into body tube        interior 1 aa (ii) so seat 5 is above and contacting ceramic        wiper 7 (iii) with top seat upper surface 5 a facing upwards.        FIGS. 2, 4C.        13. The operator thereafter rotates stem 3 to a closed position        so proximal stem curved end 3 n continuously will contact ball        component recess walls 4 k, 4 b and 4 f. FIGS. 8A and 8B.        14. The operator next places ball component 4 into body tube 1 c        through upper body tube opening 1 m, so proximal stem end 3        a (i) aligns perpendicular to ball component recess posterior        wall 4 k (ii) along longitudinal stem axis 3 i (iii) at ball        component posterior recess wall point 4 q. FIGS. 8A and 8B.        15. Seat retainer 2 is next placed upon a rigid horizontal        surface with seat retainer lowermost flat surface 2 b facing        upward.        16. The operator places bottom seat 5 into seat retainer upper        surface 2 a with bottom seat upper surface 5 a facing upwards.        FIG. 3.        17. The operator thereafter places second lower body O-ring 9 b        into lower seat retainer groove 1 o formed by first and second        seat retainer segment walls 2 f, 2 g respectively. FIGS. 3, 6.        18. The operator next places seat retainer 2 into body tube        interior 1 aa and congruently aligns retainer apertures 8 a with        tube body threaded openings 8 aa.        19. The operator next (i) applies a thread lock adhesive well        known in this industry to socket head cap threads 8 a of socket        head cap screws 8 and (ii) thereafter inserts each screw 8        through openings 8 a, 8 aa within seat retainer 2 and body tube        1 c respectively.        20. Thereafter, each socket head cap screw 8 is (i) tightened in        a circular criss-cross pattern well known in the industry        and (ii) then torqued to 45 foot-pounds.        III. Tank Installation and Operation of Ball Valve Assembly 100

Referring primarily to FIG. 1BB, installation of the assembled ballvalve assembly 100 along the bottom surface 300 a of a railroad tank car300 is a procedure well known in this particular industry, and in whichthe operator proceeds as follows:

1. He or she rotates ball component 4 to an open position using stem 3to protect ball component 4 during the installation process.

2. The operator locates rail car bottom opening 300 e through whichliquid commodity 200 (i) will flow from rail car tank 300 and (ii) intoball valve assembly 100 through upper flange opening 1 m.

3. The operator then orients ball valve assembly 100 so (i) ball valveassembly upper and lower flange openings 27 m, 25 t respectively and(ii) body tube upper and lower openings 1 m, 1 t respectivelycongruently align with rail car bottom opening 300 e.

4. A flat gasket 71 is then inserted into circular gasket groove 27 qwithin upper flange 27.

5. Ball valve assembly 100 is thereafter lifted upward towards the tankcar mounting flange surface 70 d with a suitable lifting device wellknown in this industry.

6. Drive coupling 17 is attached to stem 3 and (i) alignedlongitudinally with the rail car tank bottom flange 56 (ii) so ballvalve assembly mounting apertures 43 a congruently and concentricallyalign with tank flange mounting apertures 70 g.

7. The ball valve assembly 100 is now lifted upward until circulargasket groove 27 q engages with tank mounting flange tongue 70 b.

8. The operator next (i) inserts eight mounting bolts 43 into eachcorresponding upper flange aperture 43 a and congruently aligned tongueapertures 70 g and (ii) thereafter removes the conventional liftingdevice.

9. The operator (i) tightens mounting bolts 43 that alternate in a crisscross pattern and (ii) torques bolts 43 to 275 foot pounds as isconventionally done in this particular industry. Upper and lower flangecircular openings 27 m, 25 t respectively, as well as body tube upperand lower openings 1 m, 1 t respectively are now concentrically alignedbelow rail car circular opening 300 e. In this manner and orientationliquid commodity 200 can flow through valve assembly 100 from rail carorifice 300 e whenever ball component bore 4 a is mechanically andphysically continuous with openings 300 e, 1 m, 1 t, 27 m, and 25 t.

The opening of ball valve assembly 100 proceeds as follows:

-   -   a. After the ball valve assembly 100 is operationally assembled        and attached to rail car bottom surface 300 a as described        supra, the operator inserts a three-quarters inch square drive        tool 20 into drive coupling 17.    -   b. By grasping drive coupling handle 20 b, he or she then        rotates stem 3 counterclockwise until stop indicated plate 12        contacts stop pin 11 in an open valve position of ball component        4.    -   c. Closing of ball valve assembly 100 proceeds as follows:    -   (1) The operator inserts a three-quarters inch square drive tool        20 into drive coupling 17.    -   (2) He or she then rotates stem 3 clockwise until stop indicator        plate 12 contacts stop pin 11 in a closed position.

The above description of ball valve assembly 100 in the preferredembodiment and other embodiments does not in any manner diminish thescope of the invention to prevent leaks in other circumstances,structures and situations. The above description also does not in anymanner diminish the scope of the invention in which the same improvedfeatures are implemented within rail road tank cars or other tanks inother embodiments.

The invention claimed is:
 1. A ball valve assembly comprising a bodytube interior surface and a stem, said ball valve assembly furthercomprising valve components within said body tube interior surface, andat least two of said valve components comprising ceramic, said at leasttwo of said valve components comprising a first valve component and asecond valve component, said ceramic of said at least two of said valvecomponents not distorting or otherwise flexing or yielding upon contactof said first valve component with said second valve component, saidsecond valve component of said at least two of said valve componentscomprising a hard spherical surface, said first valve component of saidat least two of said valve components comprising a physically integraland single component device, said first valve component of said at leasttwo of said valve components being a physically distinct component fromremaining said valve components, said first valve component of said atleast two of said valve components comprising a first valve componentradially inward surface, said first valve radially inward surfacecontacting said hard spherical surface, said first valve componentradially inward surface comprising only three angled surfaces, saidfirst valve component of said at least two of said valve componentscomprising a first single middle continuously circular integralnon-distorting angled surface, said first valve component of said atleast two of said valve components further comprising a single secondsingle upper continuously circular integral non-distorting angledsurface and a third single lower continuously circular integralnon-distorting angled surface, said first single middle continuouslycircular integral non-distorting angled surface being contiguous withsaid second upper continuously circular integral non-distorting angledsurface and said third lower continuously circular integralnon-distorting angled surface, said continuously circular integralnon-distorting angled surfaces removing solids from said hard sphericalsurface, said first valve component of said at least two of said valvecomponents comprising a perpendicular cross-section, said firstcontinuous middle continuously circular integral non-distorting angledsurface comprising a first acute angle, said second single uppercontinuously circular non-distorting integral angled surface comprisinga second acute angle, and said third single lower continuously circularnon-distorting angled surface comprising a third acute angle, andwherein said first acute angle, said second acute angle and said thirdacute angle are each acute to said perpendicular cross-section of saidfirst valve component of said at least two of said valve components,said first acute angle, said second acute angle and second third acuteangle each being different from remaining said acute angles.
 2. The ballvalve assembly of claim 1 wherein said first valve component of said atleast two of said valve components comprises an annular ceramic wiper,and said annular ceramic wiper comprises an upper wiper surface, saidhard spherical surface of said second component of said at least two ofsaid valve components comprising a ball component exterior surface, saidfirst single middle continuously circular integral angled surfacecomprising a chamfer, said chamfer opening to said upper wiper surfaceat said acute angle to said wiper perpendicular cross-section, saidacute angle of said chamfer being quantitatively less than said thirdacute angle of said third single contiguous continuously circularintegral non-distorting angled surface.
 3. The ball valve assembly ofclaim 1 wherein said single second continuously circular integralnon-distorting angled surface comprises a single upper circularcontinuous bevel and said single third continuously circular-integralnon-distorting angled surface comprises a single lower circularcontinuous bevel, said upper continuous circular bevel and said lowercontinuous circular bevel each being completely contiguous with saidfirst single continuously circular integral non-distorting angledsurface, said upper circular continuous bevel comprising said firstacute angle and said lower circular continuous bevel comprising saidsecond acute angle, and wherein said first acute angle is quantitativelyless than said second acute angle.
 4. The ball valve assembly of claim 1further comprising an integral single component drive coupling, saiddrive coupling comprising a smooth integral interior surface, said drivecoupling comprising a distal smaller drive coupling channel segment anda proximal larger drive coupling channel segment, said distal smallerdrive coupling channel segment being quantitatively smaller incross-sectional dimension than said proximal larger drive couplingchannel segment, said drive coupling reversibly attaching to each of avariety of individual square drive tools by insertion of one squaredrive tool end of each of said individual square drive tools into saiddistal smaller drive coupling channel segment, and said valve stemreversibly inserting into said larger proximal drive coupling channelsegment, said drive coupling being a separate component exterior to saidassembled ball valve.
 5. The ball valve assembly of claim 1 wherein eachsaid single continuously circular integral non-distorting angled surfacedoes not comprise opposing ends that contact each other, and whereineach said single contiguously circular integral non-distorting angledsurface comprises only one single said angle.
 6. The ball valve assemblyof claim 1 wherein said first valve component of said at least two ofsaid valve components comprises an annular wiper said annular wipercomprising an exterior wiper surface and an upper wiper surface, saidannular wiper comprising a smooth continuous circular groove at theintersection of said exterior wiper surface and said upper wipersurface, said body tube interior surface comprising a continuous upperflange circular groove, said smooth continuous wiper groove beingcontiguous with said continuous upper flange circular groove, saidsmooth continuous wiper groove and said upper flange circular grooveforming a continuous smooth upper O-ring circular notch, said O-ringcircular notch exclusively containing and supporting an O-ring, saidO-ring being exclusively mechanically retained within said notch, saidO-ring circular notch comprising the sole structure for retention ofsaid O-ring.
 7. The ball valve assembly of claim 1 wherein said firstvalve component of said at least two of said valve components comprisesan annular ceramic wiper, and said wiper comprises a wiper exteriorsurface and a wiper upper surface, and wherein said second angle of saidsecond single continuously circular integral non-distorting angledsurface comprises an angle of approximately 29 degrees from saidperpendicular cross-section of said wiper.
 8. The ball valve assembly ofclaim 1 wherein said third acute angle comprises a greater quantifieddimension than said first acute angle and said second acute angle. 9.The ball valve assembly of claim 1 comprising a lower seat retainer, andsaid ceramic of said first valve component of said at least two of saidvalve components and said second valve component of said at least two ofsaid valve components comprising zirconium oxide, said zirconium oxidecomprising a Vickers hardness HV5 of 1650 kg./square millimeter and athermal expansion of 25-200 C 8.50E-06 and a tensile strength of 70-85kips.
 10. The ball valve assembly of claim 1 wherein said first valvecomponent of said at least two of said valve components removes saidsolids by scraping and pushing said solids from said hard sphericalsurface with said first, second and third continuously circular integralnon-distorting angled surfaces, said first valve component of said atleast two of said valve components not being physically attached toremaining valve components or said valve wall interior surface, saidfirst valve component continuously contacting said body tube interiorsurface and said hard spherical surface.
 11. The ball valve assembly ofclaim 1 wherein said first valve component of said at least two of saidvalve components comprises a wiper, said wiper comprising an upper wipersurface and an exterior wiper surface, said wiper comprising acontinuous circular smooth groove at the intersection of said upperwiper surface and said exterior wiper surface, said continuous circularsmooth groove creating a notch with a single continuous wall circulargroove along said body tube interior surface, said notch mechanicallyretaining a removable O-ring, said O-ring being continuously andconsistently round in cross-section and said O-ring being exclusivelymechanically retained within said notch.
 12. The ball valve assembly ofclaim 1 wherein said third lower continuously circular non-distortingangled surface comprises an angle of approximately 72 degrees from saidperpendicular cross-section of said first valve component of said atleast two of said valve components.
 13. The ball valve assembly of claim1 wherein said first single middle continuously circular integralnon-distorting angled surface comprises an angle of approximately 45degrees from said perpendicular cross-section of said first valvecomponent of said at least two of said valve components.
 14. The ballvalve assembly of claim 1 wherein said first single middle continuouslycircular integral non-distorting angled surface, said second singleupper continuously circular integral non-distorting angled surface andsaid third single lower continuously circular non-distorting angledsurface push solids away from said valve seats whenever said secondcomponent of said at least two of said valve components rotates.
 15. Theball valve assembly of claim 1 wherein said first valve component ofsaid at least two of said valve components comprises an annular wiper,said wiper comprising a minimum interior diameter of approximately 4.056inches, 4.391-inches in maximum interior diameter, 5.628 inches inmaximum exterior diameter and 0.250 inch in thickness.